Apparatus for making a casting



May 11, 1937. J.-SCHMELLER, SR

APPARATUS FOR MAKING A CASTING Filed July 5, 1935 4 Sheets-Sheet l I Awavme Jo/aw ScHMA-ZMQ 5Q ATTORNEYS May. 11, 1937'.

J. SCHM ELLER. SR

APPARATUS FOR MAKING A CASTING FilecLJuly 5, 1933 i l-j 497 4 Sheets-Sheet Jaw/v jay/154052 5e.

y 3 J. SCHMELLER, SR 2,079,749

APPARATUS FOR MAKING A CASTING I Filed July 5, 1933 4 Sheets Sheet 3 Mme-W702- JOf/A/ Sa /154452 $0 ATTOQ/VEYS Patented May 11, 1937 UNITED STATES PATENT OFFICE APPARATUS FOR MAKING A CASTING John Scluneller, Sr., Lakewood, Ohio Application July 5, 1933, Serial No. 679,030

3 Claims.

, This'invention, as indicated, relates to a casting 'and'method of and apparatus for making the same. More particularly, it comprises a cast metal article, particularly a cast metal container,- preferably made of light metal such as aluminum or alloys thereof, and preferably cast in sand molds.- It also includes the provision of a container which, if desired, may be of substantially the form of a" conventional beer barrel, wherein one head is formed integrally therewith and the other head is formed separately and united permanently or temporarily therewith, as desired, such removable head preferably carrying a fitting permanently interlocked therewith permitting the attachment of a conventional filling hose terminal and the application of a cork to the opening therethrough in the manner now generally utilized in connection with standard Barrels for beer and the like.

' Y The method broadly contemplates the casting of an article, and more especially a container, particularly one of the conventional beer barrel shape, wherein a green sand core is employed, such core being freed from the uppermost core box section as to approximately one half section preliminary to the application of the drag, and from the lowermost core box sectlon'as tothe other half section preliminary to. the application of the cope, and thereafter the assembly being ready for casting purposes. 2 Theinvention also includes the method of casting such" articles whereby a sectional mold'is employed, including molds having different arrangements so as to permit the free removal of parts thereof in a lateral direction. The core is preferablyprovided with one or more core prints apcording'to'the character of the receptacle to be formed was to permit the correct positioning of the core within the mold. The method also includes the use of a core having a single point of support wherein an article of substantially the shape of a conventional beer barrel is to be cast, the print serving not only to support the core but provide a la'rgeopening in one end of the container to provide for the attachment of an end member which, if desired, may be made separable t6 permit the cleaning or repair of the container, should the occasion require. The method also includes the ramming of the sand forming the comes a separate step, and separately forming the-casting cavities in the cope and drag section of the mold Thereafter the'separable top portion of the core box, which forms the core in reversed position, is removed and the drag section of the mold'is applied thereto. The assembled parts are then reversed end for end and the bottom portion of the core box is removed and the cope section of the mold is applied thereto. The mold is then ready for pouring the metal to form the casting.

The cope and drag sections of the mold may be separable in whole or in part to provide for vertical or horizontal gates orcombinations thereof, with suitable sprue and runner passageways to supply metal thereto, as will be hereinafter explained.

Thus where an article of substantially the shape of a conventional beer barrel is to be formed, with one end cast integrally therewith and the other end having a large opening over which an end member may be subsequently secured, when the article is completed, the integral end member will be uppermost in the mold and where the metal is fed to the casting cavity at a central parting plane of the mold, the cope is lifted upwardly when the casting operation is completed and thereafter the casting is lifted upwardly from the drag. Where other methods of supplying metal to the casting cavity are provlded, separable cope or drag members may be required, and in such case the separable cope or drag sections can be moved laterally so as to free the article from any interlocking connection with the mold. r

The invention also contemplates the manufacture of a cast metal container of barrel-like shape with an open end portion providing a support for a separate end member which may be secured thereto in a variety of ways, and also includes the supplying of a thickened portion in one of the side walls of the barrel-like container to receive a bung and providing, in the separable end member to be applied to the container, a collar adapted to be integrally united with the metal of the cover member through interlocking engagement.

The principal object of the invention, as stated, is to provide a casting, preferably in the form of an improved container having a structure affording adequate strength with a minimum of material and having an internal area free of sharp edges which would prevent thorough cleansing thereof or assist in the adherence of foreign material.

Another object of the invention is to provide a container of the type referred to wherein a somewhat cylindrical member may be provided having one end portion formed integrally therewith and the other end portion attachable thereto, whereby the container may be made with a minimum of expense and with greater facility for producing the same on a quantity basis, as a completely satisfactory article for the trade, particularly when used for' beverage purposes, such as a barrel for beer or other malt liquors.

Another object of the invention is to provide one end member of the container with a fitting adapted to cooperate with a filling hose, such fitting being interlockingly engaged with the al of the end member so as to form substanti lly an integral structure.

Another object of the invention is to provide a container of substantially beer barrel shape having a reinforced side portion to receive a bung of the conventional type.

Another object of the invention is to provide a method of and apparatus for manufacturing a casting preferably in the form of a container of somewhat cylindrical shape such as the conventional beer barrel shape, wherein the body portion of the article and one end member may be cast asan integral structure 'with the use of green sand for the core, as well as in the mold proper, in place of using other core material of higher cost and involving more time in preparation in manufacture and in manipulation preliminary to casting.

Other and further objects of the invention will appear in the course of the following description.

To the accomplishment of the foregoing and related ends, said invention then, consists of the means and method hereinafter fully described and particularly pointed out in the claims, the annexed drawings and the following description setting forth in detail certain means and modes embodying the invention, such disclosed "means and modes constituting, however, but several of various forms in which the principle of the invention may be used. )7 i In said annexed drawings: Figure 1 is an elevation with one half shown 'in section, of a barrel embodying the principles of the invention;

Figure 2 is a top plan view of the structure "shown in Figure 1, a portion thereof being shown \in section;

Figures 3,4 and 5 are fragmentary sectional views showing modified forms of connecting the end member to the body portion of the structure;

Figures 6, 7 and 8 are fragmentary sectional views, showing a barrel having reinforcing ribs -of' various types extending circumferentially thereof;

Figure 9 is a central vertical sectional view showing the cope portion of -the mold with the pattern in place, as seen along the line 9- 9, shown in Figure 10, looking in'the direction "of the arrows;

Figure 10 is a top plan view of the structure shown in Figure 9, asseen along the line I0l0, looking in the direction of the arrows;

Figure 11 is a view similar to Figure 9 showing the drag section of the mold with the pattern in place;

v Figure 12 is a top plan view showing the divided upper portion of the core boxfor producing a core for the apparatus herein illustrated;

Figure 13 is a central vertical sectional view of the core box, taken along the line 'l3i3,

box with the drag section of the mold in position;

Figure 15 is a view similar to Figure 14 showing the mold inverted, the drag section being at the base thereof; Figure 16 is a view similar to Figure 15, the lower portion of the core box having been replaced by the cope section of the mold;

Figure 17 is a. fragmentary top plan view of the casting produced in the mold illustrated in the preceding figures;

Figure 18 is a side elevation of a casting produced in the mold illustrated in the preceding Figure 19 is a'central vertical sectional view showing a modified form of mold structurewherein a sprue and riser connected with each other and with the casting, respectively, by means of thin gates are used to produce the article being manufactured;

Figure 20 is an elevation of the casting produced in the mold shown in Figure 19;

Figure 21 is a fragmentary top plan view of the structure shown in Figure 20; Figure 22 15a central vertical sectional vie of a modified form of mold having a sprue and runner connected by thingates with each other and with the casting throughout the length 0 the article being manufactured; 1 Figure 23 is a side elevation of the casting produced in the mold shown in Figure 22;

Figure 24 is a fragmentary top plan view of the structure shown in Figure 23; v Figure 25 is a central vertical sectional view of the mold supplied with circumferential runners communicating with each other and with the num or aluminum alloy. The preferred form of structure I has an integral body portion formed of a substantially cylindrical side wall 2 thickened adjacent the side 3 to form a support for a bung hole 6 and having one end or head member 5 formed integrally therewith.

The extreme ends of the casting are formed with thickened annular rims 6, Lof roughly triangular cross section to form a supporting and handling means such as is provided by the extension rim of a standardwooden beer barrel.

The integrally formed head. member 5 is preferably slightly convexed outwardly within the rim portion of the structure, and drain holes 8 are provided at spaced intervals through the annular rim portion about the circumference of: the head in line with the outer surface of such head.

Similar drain holes 9 are provided through the annular rim I heretofore'referred to. In order to assist in forming the casting, only one head member is cast integrally with the body of the barrel, the other head member being formed separately by well known conventional casting methods, and variously secured to the open end of the barrel structure. I

In the form of construction shown in Figure 1, a thickened annular inward extension H is provided on the open end'of the'barrel, which is formed with a tapered screw-thread l2 on the inner face thereof to receive a companion thread member l3 formed about the circumference of the separate head l4 of the barrel.

Theend l4, as stated, is preferably a cast member and is formed with an outwardly concaved configuration so as to conform to the integrally cast head 5 at the opposite end of the structure. Centrally of the separate head of the barrel a fitting I5 is preferably formed of brass or some metal having a chrome or nickel plated finish and interlocked with the body portion of the separate head by means of an annular recess I6 about such fitting, within which is engaged the cast metal of the separate head, such metal forming a thickened marginal portion II. The fitting is preferably formed with a central opening I! for a cork, the fitting having projecting lugs 2! of conventional type to provide a bayonet type securing means for attaching thereto the connecting member of a dispensing apparatus (not shown). The separable head'is preferably provided with a series of lugs 22 spaced adjacent its circumferential portion on its outer side to provide engaging elements for a spanner wrench or like means for removing the head from the body portion of the barrel when it is necessary to gain access to the interior thereof for purposes of cleaning the container and repairing the same.

It will be noted that the cast metal barrel illustrated is formed with rounded corners 23 at the points where the side walls meet with the end walls of the structure. thus providing greater strength at such points as well as security against the lodgment of foreign matter therein, which is the usual occurrence where a sharp corner is embodied in the structure at the meeting line of the head and body members of the structure.

As has been indicated, the separable head member may be secured to the body in various ways, and in Figures 3, 4 and 5, are illustrated three modified forms of connecting the head with the body portion of the structure. In Figure 3, the head 251s formed at its margin with a downwardly extending flange 26 formed with screw threads 21 on its inner circumference in order that it may be applied to an upstanding flange 28 formed on the inwardly extended annular rim portion .29 of the body of the structure.

In the form of construction illustrated in Figure 4, the separable head member 3| is formed with a beveled circumferential face 32 -which closely fits within an inwardly projecting annular rim 33 formed on the body portion 34 of the barrel, such rim having a beveled face 35 which in cooperation with the beveled face on the head portion of the structure provides a V-shaped channel within which a weld 38 may be formed in the usual manner.

In the modified form of construction for the separable head shown in Figure 5, the separable head member 4| is formed with a flattened marginal portion 42 provided at spaced intervals with apertures adapted to receive bolts 43. An inward annular extension 44 is provided on the body portion 45 of viding a flat face 46 on its upper side. The extension is of sufficient thickness to provide for a screw-threaded recess 41 at spaced points corresponding to the position of the bolts heretofore referred to, so that such bolts maybe firmly secured to the body portion of the structure and hold the flattened faces on the-head and rim in liquid-tight relation. If desired, a suitable packing member may be interposed between the flattened faces of the separable head and the barrel 75 structure proper.

the barrel, such extension pro- The barrel shown in Figures 1 and 2 is formed with walls of sufficient strength to withstand severe usage without reinforcement. If desired, a suitable protective covering of composition or any suitable material may be applied to the exterior of the container, for use both as an insulating means and as a protection against injury when severely handled. However, the structure as described is of suflicient strength for use without such protection.

Where a saving of metal is desired, the structure may be made of somewhat thinner gage as to the side walls of the body by providing, at intervals reinforcing ribs extending circuriiferentially about the structure. Three different types of structures are illustrated in Figures 6, '7 and 8.

In Figure 6, the central portion 5| of the body 52 of the barrel is of the greatest thickness at its point of greatest circumference, and reinforcing ribs 53, 54 are formed internally in spaced relation to the respective heads of the barrel, the intermediate wall portions of the side 55 being of thinner gage than in the constructions heretofore described.

In the structure shown in Figure '7, the body portion iii of the barrel is formed with relatively thin walled portions 62, 63 and 64, internal circumferential ribs 65 and 66 being provided intermediate such thin walled areas.

In the construction illustrated in Fig. 8, the body portion ll of the barrel is formed with thin walled portions I2, 13 and I4 with intermediate circumferential ribs 15, 16 extending about the structure intermediate the thin walled areas.

such ribs being both internal and external of the nal or combined external and internal ribs according to the particular service for which the container may be intended, and the requirements of reinforcement being conditioned upon its size and weight of the material to be placed within the.

same.

One method of construction of the apparatus heretofore described is shown in Figures 9 to 18. In such method, the entire structure is made with green sand molds, the core likewise being formed of green sand and provided with a print for supporting the same in the drag. The method of forming the cope portion of the mold is illustrated in Figure 9, wherein the pattern 8i is provided with a section 82 forming the half barrel casting cavity, the pattern having in spaced relation thereto an annular beveled rim 83 to form the circumferential runner and a thin gate 84 inwardly thereof. Suitable removable elements 85 are provided to form the sprue cavities extending from the top of the mold to the upper surface of the circumferential rim 83, such members being withdrawn as the cope section of the mold is fully rammed. By means of vent wires vent holes 86 are provided in the usual manner communicating with the highest portion of the casting cavity to permit the escape of gases formed in the usual course of operation. The upper portion 01' the flask 81 may be cylindrical or may be rectangular as shown, and any desired reinforcthe elements may be placed within the sand to suiliciently support the same in accordance with the size of the article being manufactured. The drag section of the mold is formed about a pattern 9I having a section 92 forming the other half portion of the barrel. The lower portion of the flask 93 is placed in position and the casting cavity is formed 'by ramming the sand within the space between the pattern and the lower portion of the flask in the manner shown in Figure 11. The pattern is formed with a print 96 having a beveled marginal portion 95 to provide a suitable recess to receive the print formed on the core.

As has been heretofore indicated, the core I for forming the particular container described is likewise formed of green sand, and as shown in Figures 12 and 13, is made in a core box having a separable upper section. The lower part of the core box IIII, as indicated, is formed in a single piece and serves to form the upper part of the core which cooperates with the cope section to form the lower part of the object being cast, in the present instance, as stated, a barrel. The upper part of the core box is formed in two sections I02, I03, divided on a central vertical plane in order that the narrow neck portion IM and the print I35 of the core can be formed without disturbing the supporting bottom section of the core box. If desired, the core could be produced in a two-part core box, but it could not be rammed from one end without turning the same and thus the labor of making the core and danger of injury to the same would be increased.

After the core has been formed as shown in Figure 13, the separable upper portion of the core box is removed by moving laterally the sections I02, I03, and the drag portion of the flask 93 is then applied the lower portion of the core box IBI serving in the meantime as a support for the core it. As the print I I35 engages the beveled marginal portion of the print cavity in the drag, the core will be supported in the drag in that manner. With the drag portion of the mold applied as shown in Figure 14, the assembled members are then inverted to the position shown in Figure 15, with the drag of the mold supporting the core I W and the lower portion of the core box IBI being free to be removed in an upward direction. After the removal of the lower portion of the core box, the cope section 81 of the mold is applied and the flaskis then complete and ready for the casting operation which may take place in the usual manner by pouring the metal down each of the sprue cavities I 06.

The metal as it is pouredinto the mold will enter the runner passageway It! circumferentially formed in spaced relation to the casting cavity at the central parting line of the mold, and the metal will flow through the narrow gate Hi8 into the casting cavity I09 venting through the vent holes III at the top portion of the casting cavity. After the metal has had an opportunity to solidify, thecope section.of the mold 87 is drawn upwardly, the sand of the mold being freed thereby and allowing the lifting of the casting H2 with its attached sprue metal H3, riser metal I, and runner metal II5,-and thin gate metal' attached thereto. Before the casting has completely cooled, the, excess metal may be sharp-' ly struck so as to fracture the thin gate metal circumferentially of the casting and free the same of the sprues and runners. The risers mayv be likewise fractured or sawed off in the usual manner and any fins associated with the narrow gate may be removed by any suitable finishing operations. In forming the thin gates, itis preferable to have the narrow section thereof spaced slightly outwardly from the body of the-casting in order to have the line of fracture spaced from thecasting metal surface so as to prevent the separation of the surface of the metal tearing away any of the adjacent body of the casting proper.

- In place of feeding the metal through a sprue directly into a runner communicating with the circumferential gate, the circumferential gate may be dispensed with, as shown in Figures 19 to 24, and the metal may be fed directly into the casting through a thin web extending vertically between the supply of metal and the casting cavity. In the construction shown in Figure 19, the drag section IZI of the mold is of the type shown in Figure 16, and the cope section, in place of being provided with a circumferential runner and thin gate, is formed in three parts, the upper section I22 carrying the core extension I 23 to form the depressed head section, and the intermediate portion of the cope havingtwo laterally divided portions IN meeting on a central vertical plane. The three sections of the cope when assembled are formed with sprue cavities I25 on opposite sides of the mold and with riser cavl ties I26 spaced adjacent and parallel to the respective sprue cavities. Thin gates I21 are formed between the casting cavity I29 and the respective riser cavities, and similar thin gates I28 are formed between each sprue cavity and its adjacent riser c'avity, respectively, all of such gates extending vertically throughout the intermediate core sections and the sprues and risers being in alinement with like passageways in the top core section. The number of sprues and risers may be varied 'in accordance with the size of the casting and the amount of metal to be supplied, as well as the character and temperature of the metal itself. In Figure 19, it is contemplated that the casting will be made of aluminum or aluminum alloy, and that for a container of the character described, a gate on each side will sufflce, but should more gates be required, the same can be easily supplied, such gates corresponding in structure with those described. A central.

basin connecting with each of the sprues may serve as-a single means for distributing the molten metal to each of the sprue cavities at the same time and thus require less attention to the timing of the streams of metal with reference to the several openings. The thin gates connecting the riser cavities with the casting cavity preferably extend from the central parting plane of the mold to the top of the casting cavity. The thin gates connecting the sprues with the riser cavities may extend to approximately ,the same height as the gates between the riser cavities and the casting cavity or to a greater or lesser height as particular conditions of the work may indicate to be preferable.

The casting formed in a mold of the character just described is shown in Figures 20 and 21, wherein the body of the container I33 is shown with the thingate'metal- I36 along a vertical line at each side thereof connected with the riser metal I35, which in turn is connected by means and may be formed with sprue cavities I42 and riser cavities I43 in alinement with the sprue cavities I44 and riser cavities I45 formed in the upper cope section I46 corresponding to the part I22 shown in Figure 19. Thin gates I41 serve to connect the riser cavities with the castingcavity I29, and thin gates I48 serve to connect the riser cavity with the respective sprue cavities adjat thereto, such thin gates preferably extending the height of the casting cavity.

The casting formed in a mold of the character just describedis shown in Figures 23 and 24, wherein the body of the container I5I is shown with the thin gate metal I52 along a vertical line at each side thereof extending from top to bottom of the casting connected with the riser metal I53, which in turn is connected by means of the thin gate metal I54 with the sprues I55.

In place of using pairs of vertical gates to supply metal to the casting cavity, pairs of circumferential gates may be provided in the manner shown in Figure 25. In such instance, the cope section I6I of the flask is provided with a pair of sprue passageways I62, which supply metal directly to a circumferential runner I63 formed in the cope -section at the parting line and spaced from the casting a sufficient distance to permit an inner runner I64 to be positioned concentric with the runner I63 and in the same plane therewith, and spaced one half the distance of said runner I63 from the surface of the casting cavity I65. A thin circumferential gate I66 is formed between the outer runner I63 and inner runner I64, and another thin circumferential gate I6! is formed between the inner runner I64 and the casting cavity I in the cope section at the parting plane. The gates as shown and described provide for a. complete circumferential passageway for metal into the casting cavity, but, if desired, the gates may be limited extent to any desired proportion of the complete circumference depending upon the amount of metal to be supplied to the casting cavity, the degree of thinness of the gates and the distance of the gates from the adjacent sprues. The drag section I68 of the mold just described is substantially the same as the drag section 93 shown in Figure 16.

The casting formed in the mold just described is shown in Figures 26 and 2'7, and comprises the body of the container I'II connected by means of thin circumferential gate metal I12 with the metal of the inner runner I13 which in turn is connected by the thin circumferential gate metal I'M with the outer runner I15 to which on either side is attached the sprue metal II6. As was explained in connection with the previous castings, substantially all of the accessory metal may be broken free from the container casting by sharply striking ,the same before the casting has completely cooled or by removing the same in the usual manner by sawing and grinding operations. The inner gate, as has been heretofore indicated, is preferably formed with its narrowest portion spaced slightly outwardly from the surface of the casting so that when the gate metal is fractured it will leave a thin fin on the castingand not tear away any of the body of the surface metal of the casting. The fin remaining-on the casting may be readily removed by the usual finishing methods.

The various forms of molds and various types of castings produced therein are by no means intended to be exhaustive presentation of the various types of apparatus and products which involved in the operation. Through the use ofthe pairs of narrow gates, a skimming action is brought about which allows only the more freely flowing metal to enter the casting cavity and thus a certain quantity of more slowly flowing metal carrying foreign matter and impurities may be found in the riser in one instance or in the outer or inner runner in other instances, and thus be prevented from becoming a part of the casting. Castings formed in this manner, even though there may be imperfections in the metal utilized will present a fineness of grain and a finished surface superior to castings which can be produced by other methods. Thus even though green sand is used for the material of the molds, castings having a finish and quality of metal texture corresponding to castings produced in permanent or semi-permanent molds may be fabricated with the use of green sand which is less expensive for operations of this character.

Other modes of applying the principle of my invention may be employed instead of the one explained, change being made as regards the structure herein disclosed, provided the means stated by any of the following claims or the equivalent of such stated means be employed.

I therefore particularly point out and distinctly claim as my invention:

1. An apparatus for producing metal castings with sand cores and moldswhich comprises a core box having a lower half-section and an upper member formed of two quarter-sections adapted to form a core in inverted position with a print projecting above an annular recess in the upper portion thereof, a drag section of a mold formed with substantially one half the casting cavity having a print-receiving recess adapted to be engaged, after tire removal of the upper core box quarter-sections, in supporting relation to the print of said core and a cope section formed with gates and runner cavities wholly in said cope section at the parting plane between the cope and drag sections and with a sprue passageway extending through said cope section from said runner cavity and engageable after the removal 'of the lower core box half-section over the remaining portion of said core to complete the casting cavity. W

2. An apparatus for producing castings from aluminum and its alloys with green sand mold members and a green sand core, which comprises a separable core box adapted to form a core in an inverted position with a print at the upper 5 end thereof, a removable upper portion of the core box and a preformed separable drag. section adapted to be substituted in place thereof and with a recess in said drag section receiving said print in supporting relation, and having a plu- 6 rality of vertical passageways on each side of the casting cavity with intermediate thin gates between said passageways andbetween the innermost of such passageways and the casting cavity for substantially the full extent of such casting 6 passageways in vertical alinement with the .pas- 7 sageways in said drag section to permit the introduction of molten metal into said mold through said passageways and their associated gates.

3. An apparatus for producing castings from aluminum and its alloys with green sand mold 7 members and a green sand core, which comprises a separable core box adapted to form a core in an inverted position with a print at the upper end thereof, a removable upper portion or the core'box and a preformed drag section adapted to be substituted in place thereof and with a recess in said drag section receiving said print in supporting relation, and apreformed cope section adapted to be substituted for the remain- 10 ing core box section, said cope section being provided with a plurality of circumferential runner a ing cavity and with each other and having a sprue.

cavity extending upwardly from said outermost runner cavity through the top of such cope sec-' tion to receive the molten metal and direct the same through said concentric runner cavities and gates into the casting cavity at the parting plane of the assembled mold.

JOHN SCHMELLER, Sa. 

